Patent application title: Rechargeable battery and method of manufacturing the same

Abstract:

A method of manufacturing a rechargeable battery includes continuously
supplying a first electrode plate, the first electrode plate including a
plurality of first active material portions with gaps therebetween on a
first current collector, continuously supplying a first separator and a
second separator to respective surfaces of the first electrode plate,
bending the first electrode plate with the first and second separators to
form a zigzag structure with bent portions, supplying a second electrode
plate to an inside of each bent portion of the zigzag structure, the
second electrode plate including a second active material portion on a
second current collector, aligning and stacking the first electrode
plate, the first separator, the second separator, and the second
electrode plate, and taping the aligned and stacked first electrode
plate, first separator, second separator, and second electrode plate at
an outermost side thereof.

Claims:

1. A method of manufacturing a rechargeable battery, the method
comprising: continuously supplying a first electrode plate, the first
electrode plate including a plurality of first active material portions
with gaps therebetween on a first current collector; continuously
supplying a first separator and a second separator to respective surfaces
of the first electrode plate; bending the first electrode plate with the
first and second separators to form a zigzag structure with bent
portions; supplying a second electrode plate to an inside of each bent
portion of the zigzag structure, the second electrode plate including a
second active material portion on a second current collector; aligning
and stacking the first electrode plate, the first separator, the second
separator, and the second electrode plate; and taping the aligned and
stacked first electrode plate, first separator, second separator, and
second electrode plate at an outermost side thereof.

2. The method as claimed in claim 1, wherein continuously supplying the
first separator and the second separator includes spraying an adhesive on
inner surfaces of the first separator and the second separator, the inner
surfaces facing the first electrode plate.

3. The method as claimed in claim 2, wherein continuously supplying the
first separator and the second separator further comprises attaching the
inner surfaces of the first separator and the second separator to
respective surfaces of the first electrode plate in a roll-to-roll
method.

4. The method as claimed in claim 2, wherein supplying the second
electrode plate includes spraying an adhesive on outer surfaces of the
first separator and the second separator, the outer surfaces being
opposite respective inner surfaces.

5. The method as claimed in claim 4, wherein supplying the second
electrode plate further comprises attaching the second electrode plate to
a respective outer surface of the first separator or the second
separator.

6. The method as claimed in claim 1, wherein continuously supplying the
first electrode plate includes using an electrode plate having the first
active material portions formed in a symmetrical structure on opposite
surfaces of the first current collector, the gaps between the first
active material portions corresponding to respective bent portions of the
zigzag structure.

7. The method as claimed in claim 1, wherein bending the first electrode
plate includes arranging the first active material portions, such that no
first active material portions are formed on inner surfaces of the bent
portions of the zigzag structure.

8. The method as claimed in claim 7, wherein continuously supplying the
first electrode plate includes supplying the first electrode plate with
penetration holes at the bent portions.

9. The method as claimed in claim 8, wherein aligning and stacking
includes aligning the penetration holes in the bent portions with the
second electrode plate.

10. The method as claimed in claim 1, wherein aligning and stacking
includes aligning the first electrode plate through a penetration hole in
a tab, the tab being connected to the first current collector and the
second current collector.

11. The method as claimed in claim 1, wherein continuously supplying the
first electrode plate includes integrally supplying the first electrode
plate, the first separator, and the second separator by tack welding the
first separator and the second separator on opposite surfaces of the
first electrode plate.

12. The method as claimed in claim 1, wherein supplying the second
electrode plate includes supplying the second electrode plate by tack
welding the second electrode plate to the first separator and the second
separator.

13. The method as claimed in claim 12, wherein supplying the second
electrode plate includes integrally supplying the second electrode plate
and the first separator and integrally supplying the second electrode
plate and the second separator by tack welding a pair of second electrode
plates connected to the first separator and the second separator.

14. A rechargeable battery, comprising: a first electrode plate having a
plurality of first active material portions with a gap therebetween on a
first current collector; a first separator and second separator on
respective surfaces of the first electrode plate; and a second electrode
plate on one surface of each of the first separator and the second
separator, the second electrode plate having a second active material
portion on a second current collector, and the second active material
portion corresponding to the first active material, wherein the first
electrode plate, the first separator, and the second separator are bent
in a zigzag structure with bent portions, the second electrode plate
being arranged in an inside of each bent portion of the zigzag structure
to define at least one double cell having the first electrode plate at
both sides of the one second electrode plate, and each of the first
electrode plate, the first separator, and the second separator being
integrally connected in the double cell.

15. The rechargeable battery as claimed in claim 14, wherein the first
electrode plate includes the first active material portions in a
symmetrical structure on opposite surfaces of the first current
collector.

16. The rechargeable battery as claimed in claim 14, wherein the first
electrode plate includes the first active material portions on an outer
surface of the bent portions of the zigzag structure.

17. The rechargeable battery as claimed in claim 16, wherein the first
electrode plate has penetration holes in the bent portions.

18. The rechargeable battery as claimed in claim 14, wherein the first
current collector and the second current collector are connected via a
tab, the tab including at least one penetration hole.

19. The rechargeable battery as claimed in claim 14, wherein the first
electrode plate is a negative electrode, and the second electrode plate
is a positive electrode.

Description:

BACKGROUND

[0001] 1. Field

[0002] The described technology relates generally to a rechargeable
battery and a method of manufacturing the same. More particularly, the
described technology relates generally to a rechargeable battery and a
method of manufacturing the same that improves productivity by
simplifying a manufacturing process.

[0003] 2. Description of the Related Art

[0004] A rechargeable battery includes a positive electrode plate and a
negative electrode plate in which an active material is coated on a
current collector, a separator that separates the positive electrode
plate and the negative electrode plate, an electrolyte that delivers ions
through the separator, a can (or case) that houses the positive electrode
plate, the separator, and the negative electrode plate, a lead tab that
is connected to the positive electrode plate and the negative electrode
plate to be drawn out to the outside of the can (or case), and a safety
device. An electrode assembly of a rechargeable battery may include the
positive and negative electrode plates with the separator therebetween,
and may be classified into an electrode assembly of a winding method
(jelly roll shape) and an electrode assembly of a stacking method
according to a forming method of the positive electrode plate, the
separator, and the negative electrode plate.

[0005] When the electrode assembly is manufactured by a winding method, as
the size of the positive electrode plate, the negative electrode plate,
and the separator increases, e.g., due to erroneous alignment of the
electrode plates and the separator, a failure may occur. Also, when a
length of the positive electrode plate and the negative electrode plate
increases with a capacity increase, a manufacturing time of the electrode
assembly may increase. Further, when the can of the rechargeable battery
is formed in a rectangular parallelepiped shape, upon spiral-winding of
the electrode plates and separator, due to a tension deviation between a
bent portion and a linear portion, the active material may be peeled at
the bent portions of the electrode plates and the electrode assembly may
be twisted. As such, when the can is used for a long time, battery
characteristics may deteriorate.

[0006] In the stacking method, an adhesive may be coated on both surfaces
of the separator, and a plurality of positive electrode plates and
negative electrode plates cut to a predetermined size may be alternately
stacked with the separator therebetween. However, when the electrode
assembly is manufactured via the stacking method, an additional process
of attaching the positive electrode plates and the negative electrode
plates to the separator, after previously cutting the positive electrode
plates and the negative electrode plates, may be necessary, thereby
increasing manufacturing time. Thus, manufacturing of the electrode
assembly in a stacking method may have low productivity.

[0007] The above information disclosed in this Description of the Related
Art section is only for enhancement of understanding of the background of
the described technology and therefore it may contain information that
does not form the prior art that is already known in this country to a
person of ordinary skill in the art.

SUMMARY

[0008] Embodiments are therefore directed to a rechargeable battery and a
method of manufacturing the same, which substantially overcome one or
more of the problems due to the limitations and disadvantages of the
related art.

[0009] It is therefore a feature of an embodiment to provide a
rechargeable battery and a method of manufacturing the same having
advantages of simplifying a manufacturing process and improving
productivity when alternately stacking a positive electrode plate, a
separator, and a negative electrode plate.

[0010] At least one of the above and other features and advantages may be
realized by providing a method of manufacturing a rechargeable battery,
including continuously supplying a first electrode plate, the first
electrode plate including a plurality of first active material portions
with gaps therebetween on a first current collector, continuously
supplying a first separator and a second separator to respective surfaces
of the first electrode plate, bending the first electrode plate with the
first and second separators to form a zigzag structure with bent
portions, supplying a second electrode plate to an inside of each bent
portion of the zigzag structure, the second electrode plate including a
second active material portion on a second current collector, aligning
and stacking the first electrode plate, the first separator, the second
separator, and the second electrode plate, and taping the aligned and
stacked first electrode plate, first separator, second separator, and
second electrode plate at an outermost side thereof.

[0011] The continuously supplying the first separator and the second
separator may include spraying an adhesive at opposite surfaces of the
first separator and the second separator that face the first electrode
plate.

[0012] The continuously supplying the first separator and the second
separator may further include attaching the first separator and the
second separator to respective surfaces of the first electrode plate in a
roll-to-roll method.

[0013] The supplying of the second electrode plate may include spraying an
adhesive to outer surfaces of the first separator and the second
separator that are attached to the first electrode plate.

[0014] The supplying of the second electrode plate may further include
attaching the second electrode plate to each of the first separator and
the second separator.

[0015] The continuously supplying of the first electrode plate may include
supplying the first electrode plate having the first active material
portion formed in a symmetrical structure at both surfaces of the first
current collector with a gap therebetween at which the first current
collector is bent.

[0016] The continuously supplying the first electrode plate may include
bending the first electrode plate such that the first active material is
not formed at the inside of the bent portion and the first active
material is formed at the outside of the bent portion of the first
current collector.

[0017] The continuously supplying of the first electrode plate may include
supplying the first electrode plate with a penetration hole at the bent
portions.

[0018] The aligning and stacking of the first electrode plate may include
aligning the penetration holes that are formed in the bent portions at
the second electrode plate.

[0019] The aligning and stacking of the first electrode plate may include
aligning through a penetration hole that is formed in a tab that is
connected to the first current collector and the second current
collector.

[0020] The continuously supplying the first electrode plate may include
integrally supplying the first electrode plate, the first separator, and
the second separator by tack welding the first separator and the second
separator at both surfaces of the first electrode plate that has a
plurality of first active material portions that are connected to the
first current collector.

[0021] The supplying of a second electrode plate may include supplying the
second electrode plate by tack welding the second electrode plate to the
first separator and the second separator.

[0022] The supplying of a second electrode plate may include integrally
supplying the second electrode plate and the first separator and
integrally supplying the second electrode plate and the second separator,
by tack welding a pair of second electrode plates that are connected to
the first separator and the second separator.

[0023] At least one of the above and other features and advantages may
also be realized by providing a rechargeable battery, including a first
electrode plate that has a first active material portion at the first
current collector; a first separator and second separator that are
provided at respective surfaces of the first electrode plate; and a
second electrode plate that is provided at one surface of each of the
first separator and the second separator and that has a second active
material portion corresponding to the first active material at a second
current collector, wherein the first electrode plate, the first
separator, and the second separator are bent in a zigzag state to be
stacked with the second electrode plate and form at least one double cell
by disposing the first electrode plate at both sides of the one second
electrode plate, and at the double cell, each of the first electrode
plate, the first separator, and the second separator are integrally
connected.

[0024] The first electrode plate may form the first active material
portion in a symmetrical structure at both surfaces of the first current
collector at a space between the bent portions of the first current
collector.

[0025] The first electrode plate may not have the first active material at
the inside of the bent portion and have the first active material at the
outside of the bent portion at the bent portions of the first current
collector.

[0026] The first electrode plate may have a penetration hole at the bent
portions.

[0027] The first current collector and the second current collector may
have a penetration hole that is formed in a tab.

[0028] The first electrode plate may form a negative electrode, and the
second electrode plate may form a positive electrode.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The above and other features and advantages will become more
apparent to those of ordinary skill in the art by describing in detail
exemplary embodiments with reference to the attached drawings, in which:

[0030] FIG. 1 illustrates a flowchart of a method of manufacturing a
rechargeable battery according to an exemplary embodiment;

[0031]FIG. 2 illustrates a schematic diagram of a device for
manufacturing a rechargeable battery according to an exemplary
embodiment;

[0032]FIG. 3 illustrates a side view of a first electrode plate according
to an exemplary embodiment;

[0033]FIG. 4 illustrates a detailed, enlarged view of a portion of FIG.
2, in which a second electrode plate is supplied to the first electrode
plate and the first and second separators;

[0034]FIG. 5 illustrates a partial cross-sectional view of an electrode
assembly stacked according to an exemplary embodiment;

[0035]FIG. 6 illustrates a side view of a first electrode plate according
to another exemplary embodiment;

[0036]FIG. 7 illustrates a partial top plan view of the first electrode
plate of FIG. 6;

[0037]FIG. 8 illustrates a side view of an attached state of a first
electrode plate and a first separator according to another exemplary
embodiment;

[0038]FIG. 9 illustrates a partial cross-sectional view of an electrode
assembly to which the first electrode plate of FIG. 8 is applied;

[0039] FIG. 10 illustrates a top plan view of first and second electrode
plates in which an alignment hole is formed;

[0040] FIG. 11 illustrates a side view of a first electrode plate
according to another exemplary embodiment; and

[0041] FIG. 12 illustrates a side view of an attached state of a first
electrode plate and a first separator according to another exemplary
embodiment.

DESCRIPTION OF REFERENCE NUMERALS INDICATING PRIMARY ELEMENTS IN THE
DRAWINGS

[0060] Korean Patent Application No. 10-2009-0105575, filed on Nov. 3,
2009, in the Korean Intellectual Property Office, and entitled:
"Rechargeable Battery and Method of Manufacturing the Same," is
incorporated by reference herein in its entirety.

[0061] Example embodiments will now be described more fully hereinafter
with reference to the accompanying drawings; however, they may be
embodied in different forms and should not be construed as limited to the
embodiments set forth herein. Rather, these embodiments are provided so
that this disclosure will be thorough and complete, and will fully convey
the scope of the invention to those skilled in the art.

[0062] In the drawing figures, the dimensions of layers and regions may be
exaggerated for clarity of illustration. It will also be understood that
when a layer or element is referred to as being "on" another layer or
substrate, it can be directly on the other layer or substrate, or
intervening layers may also be present. In addition, it will also be
understood that when a layer is referred to as being "between" two
layers, it can be the only layer between the two layers, or one or more
intervening layers may also be present. Like reference numerals refer to
like elements throughout.

[0063] FIG. 1 illustrates a flowchart of a method of manufacturing a
rechargeable battery according to an exemplary embodiment, and FIG. 2
illustrates a schematic diagram of a device for manufacturing a
rechargeable battery according to an exemplary embodiment. Referring to
FIGS. 1 and 2, in a method of manufacturing a rechargeable battery
according to the present exemplary embodiment, an electrode assembly may
be formed by a stacking method.

[0064] Referring to FIGS. 1 and 2, a method of manufacturing a
rechargeable battery having a first electrode plate 10, a first separator
31, a second separator 32, and a second electrode plate 20 may include a
step of supplying the first electrode plate 10 (ST10), a step of
supplying the first and second separators 31 and 32 (ST20), a step of
supplying the second electrode plate 20 (ST30), a step of aligning and
stacking the first electrode plate 10, the first separator 31, the second
separator 32, and the second electrode plate 20 (ST40), and a step of
forming an electrode assembly by taping (ST50). Each of the steps ST10 to
ST50 will be described hereinafter in detail.

[0065]FIG. 3 illustrates a side view of the first electrode plate 10
according to the first exemplary embodiment. Referring to FIG. 3, the
first electrode plate 10 may include a first current collector 11 formed
in a connection structure of a belt state, and a plurality of first
active material portions 12. The first active material portions 12 may be
formed while sustaining a gap G1 therebetween in a length direction of
the first current collector 11 at both surfaces of the first current
collector 11. That is, the first current collector 11 may have a
continuous structure, and a plurality of the first active material
portions 12 may be formed at constant intervals, i.e., gaps G1, along a
longitudinal direction of the first current collector 11 on each surface
of the first current collector 11. The first active material portions 12
may be symmetrically formed on both surfaces of the first current
collector 11, e.g., each pair of first active material portions 12 facing
each other from opposite surfaces of the first current collector 11 may
completely overlap each other, so the gaps G1 on one surface of the first
current collector 11 may be aligned with the gaps G1 on an opposite
surface of the first current collector 11.

[0066] The step of supplying the first electrode plate 10 (ST10) may
include a continuous supply of the first electrode plate 10 illustrated
in FIG. 3. In detail, as illustrated in FIG. 2, the first electrode plate
10 may be continuously supplied, e.g., without cutting portions thereof,
while being bent in a zigzag manner with a roll-to-roll method. That is,
the first electrode plate 10 may be formed to be bent at portions of the
first current collector 11 between adjacent first active material
portions 12, i.e., at the gaps G1.

[0067] The step of supplying the first and second separators 31 and 32
(ST20) may include supply of the first and second separators 31 and 32 to
both respective surfaces of the first current collector 11 of the first
electrode plate 10. In detail, as illustrated in FIG. 2, the first
separator 31 and the second separator 32 may be bent in a zigzag state
with a roll-to-roll method, and may be continuously supplied at
respective sides of the first electrode plate 10.

[0068] As further illustrated in FIG. 2, the first electrode plate 10 and
the first and second separators 31 and 32 may be respectively directed
around first rolls 41, 42, and 43, and may be bent through common second
and third rolls 44 and 45. The third roll 45 may be offset horizontally
with respect to the second roll 44 in order to bend the first electrode
plate 10 and the first and second separators 31 and 32. It is noted that
a horizontal direction refers to a lateral direction of FIG. 2 that is
substantially perpendicular to a supply direction, i.e., vertical
direction of FIG. 2.

[0069] Further, the step of supplying the first and second separators 31
and 32 (ST20) may include a step of spraying a first adhesive and a first
attaching step. In detail, as illustrated in FIG. 2, the step of spraying
the first adhesive may include spraying an adhesive by dispensers 33 and
34 to inner surfaces of the first separator 31 and the second separator
32, i.e., surfaces facing respective opposite surfaces of the first
electrode plate 10. The first attaching step may include attaching the
inner surfaces of the first and second separators 31 and 32 to respective
surfaces of the first electrode plate 10 in a roll-to-roll method, as
illustrated in FIG. 2. The dispensers 33 and 34 may be installed between
the first rolls 41, 42, and 43 and the second roll 44 to perform the step
of spraying the first adhesive before the first and second separators 31
and 32 contact the first electrode plate 10 at the second roll 44. After
the step of spraying the first adhesive, the first attaching step is
performed when the first electrode plate 10 and the first and second
separators 31 and 32 closely contact each other to pass by the second
roll 44.

[0070]FIG. 4 illustrates a detailed, enlarged view of a process in FIG.
2, in which the first electrode plate 10 and the first and second
separators 31 and 32 are bent, and the second electrode plate 20 is
supplied. Referring to FIGS. 2 and 4, the step of supplying the second
electrode plate 20 (ST30) includes supplying the second electrode plate
20 to one surface of each of first and second separators 31 and 32. In
detail, as illustrated in FIG. 4, the second electrode plate 20 may be
formed as a second current collector 21 with a second active material
portion 22 provided at both surfaces thereof. The second electrode plate
20 may include individual, i.e., discrete, second electrode plates 20
alternately inserted to an inside of each zigzag portion of the bent
first electrode plate 10 and adjacent to the respective first and second
separators 31 and 32 on the opposite side to the first active material
portions 12.

[0071] That is, as illustrated in FIG. 2, the first electrode plate 10 and
the first and second separators 31 and 32 may be attached by the second
and third rolls 44 and 45 to be bent in a zigzag state. In other words,
the first electrode plate 10 may be between the first and second
separators 31 and 32, and may be bent with each of the first and second
separators 31 and 32 to have sharp turns in alternating directions. As
illustrated in FIGS. 2 and 4, the second electrode plates 20 may be
alternately supplied at the outsides of the first and second separators
31 and 32 by supply units 50 provided at both sides of the first
electrode plate 10. For example, as illustrated in FIG. 2, one individual
second electrode plate 20 may be supplied by the left supply unit 50 (in
FIG. 2) into, e.g., each, zigzag bend facing the left supply unit 50 to
contact the first separator 31. In another example, as illustrated in
FIG. 2, one individual second electrode plate 20 may be supplied by the
right supply unit 50 (in FIG. 2) into, e.g., each, zigzag bend facing the
right supply unit 50 to contact the second separator 32.

[0072] Therefore, the first electrode plate 10 and the first and second
separators 31 and 32 may have a second electrode plate 20 at each of
spaces between the first and second separators 31 and 32, and thus, the
first electrode plate 10 and the second electrode plate 20 may be
alternately stacked. For example, as illustrated in FIG. 4, positioning
one individual second electrode plate 20 inside each zigzag bend, i.e., a
bend defined by two adjacent first active material portions 12 of the
first electrode plate 10, may provide an alternating arrangement of first
and second electrode plates 10 and 20, i.e., one second electrode plate
20 between two first electrode plates 10.

[0073] Further, the step of supplying the second electrode plates 20
(ST30) may include a step of spraying a second adhesive and a second
attaching step. The step of spraying the second adhesive may include
spraying an adhesive by dispensers 35 and 36 at outer surfaces of the
first and second separators 31 and 32, i.e., surfaces opposite respective
inner surfaces, opposite those that are attached to the first electrode
plate 10. The second attaching step may include alternately attaching the
second electrode plates 20 to the first and second separators 31 and 32,
i.e., to surfaces sprayed with the second adhesive. While the second
electrode plates 20 are inserted and the first electrode plate 10 and the
first and second separators 31 and 32 are stacked, the second electrode
plates 20 may be attached to each of the first and second separators 31
and 33.

[0074]FIG. 5 illustrates a partial cross-sectional view of an electrode
assembly including a stacked structure of the first and second electrode
plates 10 and 20 with the first and second separators 31 and 32
therebetween. It is noted that the structure illustrated in FIG. 5 is a
state after stacking and alignment is complete, i.e., after the process
of FIG. 4.

[0075] Referring to FIG. 5, in the step of aligning/stacking (ST40), the
bent first electrode plate 10, first and second separators 31 and 32, and
second electrode plate 20 may be aligned and stacked. The first electrode
plate 10, the first and second separators 31 and 32, and the second
electrode plate 20 may be aligned by adjusting tension of the supplied
first electrode plate 10 and the first and second separators 31 and 32.
For example, the tension of the supplied first electrode plate 10 and the
first and second separators 31 and 32 may be adjusted, so opposite
surfaces of each second electrode plate 20 may completely overlap and be
in direct contact with respective surfaces of the first and/or second
separators 31 and 32. As such, the first and second electrode plates 10
and 20 may be arranged to, e.g., completely, overlap each other, e.g.,
first and second active material portions 12 and 22 may completely
overlap each other, so respective terminal edges of the first and second
electrode plates 10 and 20 may be aligned. Alignment of the edges will be
described in more detail below with reference to FIG. 10.

[0076] At the taping step (ST50), as illustrated in FIG. 5, the first
electrode plate 10, the first and second separators 31 and 32, and the
second electrode plate 20, in which aligning and stacking are complete,
may be taped with a tape 51 at an outermost side to form an electrode
assembly 1. Therefore, the first electrode plate 10, the first and second
separators 31 and 32, and the second electrode plate 20 may not move or
twist in the electrode assembly 1 of a stacked state.

[0077] In the electrode assembly 1, the first electrode plate 10 may be a
positive electrode or a negative electrode, and in this case, the second
electrode plate 20 may be a negative electrode or a positive electrode,
i.e., opposite in polarity to the first electrode plate 10. Because the
first electrode plate 10 is connected to the first current collector 11,
when the first electrode plate 10 is a negative electrode and the second
electrode plate 20 is a positive electrode, safety for a short circuit of
the electrode assembly 1 may be further improved, as compared with a case
where the first electrode plate forms a positive electrode and the second
electrode plate forms a negative electrode.

[0078] In a full cell that forms a rechargeable battery according to the
present exemplary embodiment, the first electrode plate 10 and the first
and second separators 31 and 32 may be bent in a zigzag state to be
stacked with the second electrode plate 20. By disposing the first
electrode plate 10 at both sides of one second electrode plate 20, one or
a plurality of double cells (DC) may be formed. The DC may include two
unit cells.

[0079] In the DC, because the first electrode plate 10 and the first and
second separators 31 and 32 are each integrally connected, when stacking
the first electrode plate 10, the first and second separators 31 and 32,
and the second electrode plate 20, a manufacturing process may be
simplified and productivity may be improved.

[0080]FIG. 6 illustrates a side view of a first electrode plate according
to a second exemplary embodiment. FIG. 7 illustrates a partial top plan
view of the first electrode plate of FIG. 6.

[0081] Referring to FIG. 6, a first electrode plate 210 according to the
second exemplary embodiment may include bent portions 11a and 11b at both
sides of a bent first current collector 11. Therefore, at the step of
supplying the first electrode plate 210, a first active material 212 may
not provided at the inside of the bent portions 11a and 11b, so the first
active material portion 212 may be supplied at the outside of the bent
portions 11a and 11b. For example, the first electrode plate 210 may be
bent at the bent portion 11b, so a portion of the first active material
portion 212 adjacent one bent portion 11a may face a portion of the first
active material portion 212 adjacent an adjacent bent portion 11a. As
such, an inside of the bent portion 11b, i.e., a surface of the first
current collector 11 opposite a surface including the bent portion 11b,
may not include the first active material portion 212. Because the first
active material 212 is not be provided at the inside of the bent portions
11a and 11b, when the first current collector 11 is bent, the first
active material 212 may not be separated from the inside of the bent
portions 11a and 11b. Therefore, characteristics of the battery may be
prevented from being deteriorated. As the first active material portion
212 in the first electrode plate 210 is continuously provided at the
outside of the bent portions, an area of the first active material
portion 212 may be larger than that of the active material portion 12 in
the first electrode plate 10 described previously with reference to FIG.
3, thereby increasing capacity of the battery.

[0082] Further, the first electrode plate 210 may include a penetration
hole 11c at the bent portions 11a and 11b that are formed at both sides.
Therefore, even if the first active material portion 212 is formed at the
outside of the bent portions 11a and 11b, when an electrolyte is used, a
flow path may be secured via the penetration hole 11c. Therefore, the
electrolyte may smoothly penetrate the first and second electrode plates
210 and 20. A plurality of penetration holes 11c may be formed in a width
direction of the first electrode plate 210. Therefore, according to the
second exemplary embodiment, at the step of supplying the first electrode
plate, the first electrode plate 210, i.e., with a previously formed
penetration hole 11c, may be supplied to be bent at the bent portions 11a
and 11b.

[0083]FIG. 8 illustrates a side view of an attached state of a first
electrode plate and a first separator according to a third exemplary
embodiment. Referring to FIG. 8, at the step of supplying the first
electrode plate, by previously tack welding the first and second
separators 31 and 32 at respective surfaces of the first electrode plate
210 according to the second exemplary embodiment, the first electrode
plate 210 and the first and second separators 31 and 32 may be integrally
supplied. Therefore, a process of supplying the first electrode plate 210
and the first and second separators 31 and 32 may be performed more
simply, e.g., simultaneously, than that of the first exemplary
embodiment, i.e., described previously with reference to FIGS. 1-5.

[0084]FIG. 9 illustrates a partial cross-sectional view of an electrode
assembly 2 including the first electrode plate of FIG. 8. Referring to
FIG. 9, in the third exemplary embodiment, the step of aligning/stacking
may include aligning the penetration holes 11c that are formed in the
bent portions 11a and 11b with the second electrode plate 20, so a flow
path of an electrolyte may be formed. At the electrode assembly 2, by
forming the penetration hole 11c in the first active material portion 212
that is formed at the outside of the bent portions 11a and 11b of the
first electrode plate 210, a flow path of an electrolyte to be penetrated
to the second electrode plate 20 may be completed.

[0085] FIG. 10 illustrates a top plan view of the first and second
electrode plates 10 and 20 in which an alignment hole is formed.
Referring to FIG. 10, a penetration hole 14 may be formed in a tab 13
that is connected to the first and second current collectors 11 and 21 of
the first and second electrode plates 10 and 20. At a tab notching
process, the penetration hole 14 may be formed in a non-coating area that
is used as the tab 13.

[0086] When a plurality of the first and second electrode plates 10 and 20
are stacked, the penetration hole 14 may allow the first and second
electrode plates 10 and 20 to be easily stacked and aligned at an upper
part and a lower part of a stacking direction. Further, upon stacking and
aligning the first and second electrode plates 10 and 20, the first and
second electrode plates 10 and 20 may be aligned based on an end surface
edge thereof.

[0087] At the aligning/stacking step (ST40), the first and second
electrode plates 10 and 20 may be aligned in a stacking direction through
the penetration hole 14, and the first and second electrode plates 10 and
20 may be aligned through an end surface edge thereof, thereby enabling
more accurate alignment. The aligned tabs 13 may be welded to a lead tab
(not shown) of the rechargeable battery.

[0088] FIG. 11 illustrates a side view of a first electrode plate
according to a fourth exemplary embodiment. Referring to FIG. 11, the
step of supplying the second electrode plate 20 may include tack welding
the second electrode plate 20 to the first separator 31 and the second
separator 32. Therefore, at one side of the first electrode plate 10, the
second electrode plate 20 and the first separator 31 may be integrally
supplied, and at the other side of the first electrode plate 10, the
second electrode plate 20 and the second separator 32 may be integrally
supplied. In the fourth exemplary embodiment, the first and second
electrode plates 10 and 20 and the first and second separators 31 and 32
may be easily supplied, as compared with the first exemplary embodiment.
Substantially, the first and second separators 31 and 32 and the second
electrode plate 20 may be simultaneously supplied.

[0089] FIG. 12 illustrates a side view of an attached state of a first
electrode plate and a first separator according to a fifth exemplary
embodiment. Referring to FIG. 12, in the step of supplying the second
electrode plate, while sustaining a gap G2, by tack welding a pair of
second electrode plates 520 that are connected to the first separator 31,
the second electrode plate 520 and the first separator 31 may be
integrally supplied. Further, in the step of supplying the second
electrode plate, while sustaining a gap, by tack welding a pair of second
electrode plates that are connected to the second separator, the second
electrode plate and the second separator may be integrally supplied (not
shown). In this case, in a full cell, the DCs may be connected in
parallel in a stacking direction.

[0090] According to exemplary embodiments, by continuously supplying and
bending the first electrode plate and the first and second separators in
a zigzag state, followed by providing the second electrode plate between
the first separator or the second separator, and stacking and aligning
them, a unit cell and a full cell may be formed, thereby simplifying the
manufacturing process, e.g., eliminating a need of separately cutting and
attaching the first electrode plate. Because a full cell is formed by
continuously stacking unit cells, productivity may be improved, and
capacity may be changed by changing the stacking quantity of the first
and second electrode plates, thereby easily adjusting the battery to a
size change of a product.

[0091] Exemplary embodiments have been disclosed herein, and although
specific terms are employed, they are used and are to be interpreted in a
generic and descriptive sense only and not for purpose of limitation.
Accordingly, it will be understood by those of ordinary skill in the art
that various changes in form and details may be made without departing
from the spirit and scope of the present invention as set forth in the
following claims.